How to optimize the gear processing accuracy and noise control of the R series helical gear reduction motor?

1. How to control the gear processing accuracy of the R series helical gear reduction motor?

In the modern industrial field, the R series helical gear reduction motor is widely used in many scenarios such as automated production lines and logistics transportation equipment due to its efficient and stable transmission performance. As the core factor affecting the transmission efficiency and service life of the reduction motor, the quality of its control technology is crucial. Tooth profile error, tooth direction error and tooth pitch cumulative error are key indicators for measuring gear processing accuracy. The slight change of each error may be magnified during the operation of the motor, thereby affecting the performance of the entire system. ​
High-precision processing equipment is the basic guarantee for controlling gear processing accuracy. High-precision gear hobbing machines and gear grinding machines play a key role in the gear processing of the R series helical gear reduction motor. The gear hobbing machine cuts out the involute tooth shape according to the principle of the generation method through the relative movement of the hob and the gear blank. Its high-precision transmission system and control system can ensure the stability and accuracy of the processing process. Gear grinding machines are used to finish gears to further improve tooth profile accuracy and surface quality. They can effectively correct errors generated during gear hobbing and enable gears to reach higher levels of accuracy. For example, when processing high-precision helical gears, gear grinding machines can control tooth profile errors within a very small range to ensure the stability of gears during meshing. ​
Full-process quality monitoring is an important means to ensure gear processing accuracy. Coordinate measuring machines (CMMs) and gear testing centers play the role of "quality guards" in the gear processing process. Coordinate measuring machines accurately measure the geometric dimensions, shapes, and position accuracy of gears by contact or non-contact methods, and can quickly and accurately obtain various parameters of gears and compare and analyze them with design standards. The gear testing center focuses on professional gear testing, which can not only detect tooth profile errors, tooth guide errors, and pitch cumulative errors, but also evaluate indicators such as contact spots and tooth surface roughness of gears. In actual production, by testing gears after key processes, problems in the processing process can be discovered in a timely manner, and adjustments and corrections can be made to prevent unqualified products from flowing into the next process.​
Tool wear compensation and heat treatment deformation control are important links to ensure gear processing accuracy. During the gear processing process, the tool will gradually wear as the processing time increases. Tool wear will cause the size and shape of the processed gear to change, thus affecting the processing accuracy. Therefore, it is necessary to establish a tool wear model to monitor the wear of the tool in real time, and automatically adjust the processing parameters according to the degree of wear to compensate for tool wear to ensure the processing accuracy of the gear. Heat treatment is an important process to improve the mechanical properties of gears, but the deformation generated during heat treatment will also affect the gear accuracy. By optimizing the heat treatment process parameters, such as heating speed, holding time, cooling method, etc., and adopting a suitable clamping method, the heat treatment deformation can be effectively controlled to ensure that the gear can still maintain a high accuracy after heat treatment. ​

2. What are the noise control measures for R series helical gear reduction motors? ​

In the performance evaluation system of R series helical gear reduction motors, noise level is an important indicator that cannot be ignored. The noise generated during the operation of the motor will not only pollute the working environment and affect the physical and mental health of the operator, but may also reflect potential problems inside the motor, such as gear wear and improper assembly. The motor noise mainly comes from gear meshing, bearing operation and structural vibration. For these noise sources, a series of effective control measures need to be taken. ​
Gear modification is a key technical means to reduce gear meshing noise. Micro tip relief and profile modification can effectively reduce the impact vibration of gears during meshing. Micro tip relief is to perform a slight trimming on the top of the gear teeth to avoid the instantaneous impact caused by the interference of the top of the gear teeth when the gear enters and exits the meshing, thereby reducing vibration and noise. Profile modification is to optimize the tooth profile curve according to the actual working conditions and load characteristics of the gear, so that the load distribution of the gear during meshing is more uniform, reducing vibration and noise. For example, under high-speed and heavy-load conditions, reasonable profile modification can significantly improve the meshing performance of the gear and reduce the generation of noise. ​
High-precision assembly is an important part of controlling motor noise. The size of the gear meshing clearance directly affects the running noise of the motor. If the meshing clearance is too small, the gear will generate greater friction and heat during operation, resulting in abnormal noise and increased wear; if the meshing clearance is too large, gear collision will occur, which will also generate noise. Therefore, during the assembly process, it is necessary to strictly control the installation position and meshing clearance of the gears, and ensure the accuracy and stability of the gear meshing through precise measurement and adjustment. At the same time, the installation of bearings and other components also needs to be carried out in strict accordance with the process requirements to ensure that the concentricity and preload of the bearings are appropriate to avoid noise caused by improper bearing installation. ​
Vibration reduction design is an effective way to reduce the vibration noise of the motor structure. The use of a high-rigidity box structure can enhance the overall rigidity of the motor and reduce vibration during operation. Optimizing the bearing support method, such as using multi-point support, elastic support, etc., can reduce the transmission of bearing vibration and reduce the risk of resonance. In addition, adding vibration reduction materials or vibration reduction devices, such as rubber vibration reduction pads, dampers, etc., to the key parts of the motor can also effectively absorb and dissipate vibration energy and reduce noise levels. For example, installing a rubber vibration reduction pad between the motor housing and the mounting foundation can isolate the transmission of motor vibration to the foundation and reduce noise caused by vibration.​
Lubrication optimization plays an important role in reducing motor noise. The use of low-noise grease can reduce friction and wear of gears and bearings during operation and reduce noise. At the same time, it is crucial to ensure that the oil film of the lubrication system evenly covers the tooth surface and bearing surface. Reasonable design of the oil circuit and lubrication method of the lubrication system, such as forced lubrication and circulating lubrication, can ensure that the lubricating oil can reach each lubrication part in a timely and sufficient manner to form a good lubrication state. In addition, regular maintenance and care of the lubrication system and timely replacement of aging or deteriorated grease can also ensure the normal operation of the lubrication system and effectively control motor noise.